Method of forming a composite panel

ABSTRACT

A method of forming a composite panel with a facade comprising a planar arrangement of thin discrete facers on a body of structural backing material. The method comprises the steps of providing a horizontal casting bed, providing a plurality of facers each with a chamfer at a corner between side and rear walls. Arranging the plurality of facers in abutting relationship atop the casting bed and in a selected pattern in a face down planar configuration so that the chamfers on the facers open upwardly and define narrow elongated sealant channels at joints between contiguous facers. Depositing a sealant in the channels and pouring concrete as a structural backing material atop the facers, the rear surfaces of the facers and the concrete adhering to form a composite panel.

FIELD OF THE INVENTION

[0001] This invention is directed to a method of forming a compositepanel with a facade comprising a planar arrangement of thin discretefacers on a body of a structural backing material.

BACKGROUND OF THE INVENTION

[0002] Composite concrete and other panels have been in use for a numberof years but have not been entirely satisfactory. A bare concrete panel,for example, may be found lacking aesthetically or in othercharacteristics such as resistance to certain chemicals, durability,high heat gain from the sun, dirt or grime resistance, etc. Accordingly,a number of methods have been proposed to provide finishes for the frontsurfaces of panels in order to improve their aesthetic and architecturalappearance or other properties.

[0003] For example, a number of different methods have been tried tocast in place or otherwise adhere discrete facing units or “facers” onthe front surfaces of panels in finished concrete structures. As is wellknown, different methods have been employed in holding individual facersin a desired pattern, usually in a common horizontal plane, whileconcrete is cast over and about them so as to at least partially embedthem in a wall or other panel. Facers such as thin concrete unitsmanufactured on masonry block machines may be employed in accordancewith the present invention together with bricks, tiles, natural stone,concrete pavers, etc. to provide a visually pleasing appearance or tomeet functional or other requirements.

[0004] In manufacturing composite walls, it has been a conventionalpractice to provide various types of forms, grids etc. in securing thefacers in position prior to placing concrete or other structuralmaterial thereover. However, such methods have not been whollysatisfactory. For example, leakage of concrete between facers may resultin concrete adhering to the faces of the latter and in substantial addedexpense in subsequent removal thereof. Such prior methods have failed toachieve economic advantage due to complicated and tedious manual stepsinvolved in assembling and removing forms, grids, etc. Obviously,grouting between facers is also required in some designs when the panelis complete.

[0005] It is a general object of the present invention to provide asimplified method for making high quality composite walls and otherpanels at economic advantage and which yet results in a cleanaesthetically pleasing final appearance or improved functional surfaceof the facer surfaced wall or other panel.

[0006] A further object of the invention resides in a method of making acomposite panel which obviates the need for grouting between facers onthe panel.

[0007] A still further object is to provide a simplified method whichrequires minimum manpower and yet provides a panel pleasing inappearance or improved functional surface and which exhibits a highdegree of structural integrity.

SUMMARY OF INVENTION

[0008] In fulfillment of the foregoing objects and in accordance withthe present invention, a method of forming a composite wall or otherpanel with a planar arrangement of thin discrete facers on a structuralbacking material comprises the steps of providing a flat preferablyhorizontal casting bed which may be of either a rigid or deformablematerial. The ability of the casting bed to deform allows thearrangement of facers accurately in a common plane despiteirregularities which may occur on the front faces thereof. Plastic foamor other similar materials may be employed in forming such a casting bedbut a fine particulate material in the form of sand is presentlypreferred with a horizontal casting bed. When facers with smooth flatfaces lacking significant irregularities are employed, a rigid or hardsurface casting bed may of course be employed preferably with heavypaper, plastic sheet or thin plastic foam thereover.

[0009] A plurality of facers each with a chamfer, bevel, or other recessalong at least a major portion of the corner between its' side walls,end walls and rear wall are provided and arranged with the facers intight abutting relationship and face down on the casting bed. Variousgeometric patterns may be employed but the facers are in all casespositioned in a face down attitude and in a common plane, so that theaforesaid chamfers or other recesses open rearwardly or upwardly todefine narrow elongated channels at the joints between all contiguousfacers. Certain of the channels with two adjacent opposing chamfers maytake “V” configurations in cross-section while others with only onechamfer may take one half (½) “V” configurations in cross-section.

[0010] The chamfers or other recess forming configurations providenarrow elongated arcuate, angular or vertical surfaces which are engagedby concrete or other backing material to form a seal which preventswater from thereafter seeping behind the facers. In the absence of sucha seal, subsequent freezing and thawing may loosen and even cause facersto break away from the structural backing material.

[0011] In addition to the foregoing, sealant may be placed in theelongated recesses or channels and may also take a variety of forms. Forexample, elongated unitary sealing members, hardenable liquids, or fineparticulate materials such as sand may be used, the latter beingpresently preferred. A castable structural backing material such asconcrete or other cementitious material is then placed or pouredrearwardly of the facers and both conforms to and adheres to the rearsurfaces thereof as it cures and hardens. A composite wall or otherpanel is thus formed and may then be moved to its operative position.For example, if the panel takes the form of a tilt-up wall formedhorizontally, an upward swinging movement through 90° may be effectedfrom its horizontal casting bed.

[0012] Generally, the facers have a rectangular configuration and therear corners thereof are beveled or chamfered at corners between eachend wall and their rear walls and at least one side wall and rear wallcorner. Chamfers or other recesses may take various configurationsviewed in cross-section including rectangular and arcuate, but a flatangularly inclined surface extending between adjacent right angularlyrelated side or end and rear facer surfaces is preferred. When a sealantsuch as sand is employed, a subsidiary method step may take the form ofdepositing sand on the rear surfaces of the facers and sweeping the sameinto the sealant channels with the remainder of the facer rear surfacesbeing cleaned for good adhesion of the concrete.

[0013] Preferably, the rear surfaces of the facers are also providedwith integral rearwardly and upwardly projecting structural connectingmeans which are enveloped during the pouring of concrete and thereafterfirmly embedded in the cured concrete for enhanced structural integrityof the wall or other panel. Such walls or other panels are found to besubstantially stronger than walls or panels without facers and may evenapproach the strength of monolithic concrete walls or panels of equaloverall thickness. The connecting means presently take the form of aseries of spaced apart parallel ribs integral with the bodies of thefacers. Further, the ribs are preferably formed as shown with dove-tailconfigurations in cross-section defining complementary generallydove-tail grooves therebetween.

[0014] Still further in accordance with the preferred form of theinvention, a plurality of spring clips are provided to interconnect theaforementioned ribs. Some of the clips may be installed ininterconnecting relationship on aligned ribs of contiguous facersarranged in end-to-end relationship and others on contiguous half ribsarranged in side-by-side relationship on adjacent facers in likerelationship. The clips are preferably of generally dove-tailconfiguration viewed in cross-section with short opposing side legsdefining entry openings for the dove-tailed ribs. Further, the legs ofeach clip are inwardly inclined toward the mouth of the clip opening sothat the clips may be snapped into firm embracing engagement on the ribsin relative movement toward the ribs. Thereafter the clips serve to urgefacers and especially the side-by-side facers firmly together inabutting engagement to prevent concrete leakage downwardlythere-between.

[0015] Further, the clips also maintain the facers in a common planepreventing accidental or unintended displacement of individual facers.Still further, the clips aid in urging facers having uneven frontsurfaces and facers improperly positioned toward a common plane.

[0016] A tool of appropriate design may also be provided for ease ofconvenience in the assembly of the clips on the ribs.

[0017] Finally, a plurality of upstanding anchors may be provided withbase portions mounted on the ribs of the facers and supports forhorizontal reinforcing members such as “re-bars” may also be providedwith the latter also mounted on rear surfaces of the facers inengagement with ribs and inter-rib grooves.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018]FIG. 1 is a side view of a “facer” constructed in accordance withthe present invention.

[0019]FIG. 2 is a front view of the facer of FIG. 1.

[0020]FIG. 3 is a view taken from the end of the facer.

[0021]FIG. 4 is a perspective view of the rear surface of the facer.

[0022]FIG. 5 is a side view of a partially constructed wall with facersdisposed atop a casting bed of sand in abutting relationship and withone-half (½) “Y” sealant channels between facers.

[0023]FIG. 6 is a fragmentary enlarged view of a facer joint taken fromFIG. 5.

[0024]FIG. 7 is a view similar to FIG. 5 but with sand disposed in thesealant channels.

[0025]FIG. 8 is a fragmentary enlarged view of an inter-facer joint asin FIG. 6 but with sand deposited in the sealing channel.

[0026]FIG. 9 is a side view similar to FIG. 5 and 7 but with concretedeposited atop the facers.

[0027]FIG. 10 is a fragmentary enlarged view of a facer joint asillustrated in FIG. 9.

[0028]FIG. 11 is enlarged fragmentary view of a facer joint as in FIG. 6but with an Y-shaped sealant channel.

[0029]FIG. 12 is similar to FIG. 11 but with sand deposited in thechannel as a sealant.

[0030]FIG. 13 is a view similar to FIG. 11 and 12 but with structuralmaterial deposited atop the facers.

[0031]FIG. 14 is a perspective view of a plurality of facers positionedin face down abutting relationship and partially forming the frontsection of a panel, spring clips being mounted on ribs which projectupwardly from the facers.

[0032]FIG. 15 is an enlarged perspective view showing an individualspring clip.

[0033]FIG. 16 is a top view of an alternative clip.

[0034]FIG. 17 is a perspective view of the spring clip of FIG. 16.

[0035]FIG. 18 is a side view of the spring clip of FIG. 16, 17.

[0036]FIG. 19 is a side view of an anchor adapted to be mounted on aback surface of a facer.

[0037]FIG. 20 is an opposite side view of the anchor of FIG. 19.

[0038]FIG. 21 is a perspective view of the anchor of FIGS. 19 and 20.

[0039]FIG. 22 is a top view of the anchor.

[0040]FIG. 23 is a top view of a “chair” for supporting elongatedconcrete reinforcing members or “re-bars”.

[0041]FIG. 24 is a perspective view of the re-bar chair of FIG. 23.

[0042]FIG. 25 is a side view of the chair.

[0043]FIG. 26 is another side view better showing an upwardly opengroove for receiving and supporting a re-bar.

[0044]FIG. 27 is a perspective view showing a number of facers withchairs mounted thereon as in FIGS. 23-26, the chairs being shown withtheir legs spring mounted in the dove-tail grooves of the facers.

[0045]FIG. 28 is a side view showing the chair supporting rightangularly arranged re-bars.

[0046]FIG. 29 is an enlarged perspective view showing a chair mounting apair of right angularly arranged re-bars.

[0047]FIG. 30 is a top view of a chair having three mounting groovesarranged in alignment with three opposite grooves; thus, three re-barsbeing accommodated in right angular arrangement with three additionalre-bars.

[0048]FIG. 31 is a perspective view of the re-bar chair of FIG. 30.

[0049]FIG. 32 is a first side view of the re-bar chair of FIGS. 30 and31.

[0050]FIG. 33 is a second and opposite side view of the chair.

[0051]FIG. 34 is a perspective view of the chair of FIGS. 30-33 with asingle re-bar mounted thereon in each right angular direction and withthe base portion of the chair mounted in embracing relationship on ribson the back of a facer.

[0052]FIG. 35 is a perspective view similar to FIG. 34 but with a baseportion of the chair entered in and engaging the opposite side-walls ofan inter-rib groove.

[0053]FIG. 36 is a perspective view showing a number of facers with alarge chair having three aligned grooves in one direction and fivealigned grooves in right angular arrangement therewith.

[0054]FIG. 37 is a side view of a tool for installing spring clips withan associated clip shown in an expanded condition.

[0055]FIG. 38 is a similar view of the same tool with the clip in acontracted position.

[0056]FIG. 39 is a perspective view illustrating operation of the toolin respect to a spring clip.

[0057]FIG. 40 is a top view of the tool of FIGS. 37-39; and

[0058]FIG. 41 is a perspective view of an insulated panel constructed inaccordance with the method of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0059] Referring now particulary to FIGS. 1-4, a facing unit or “facer”is illustrated generally therein at 10 in a presently preferred form. Asmentioned above, facers may take a wide variety of forms including thinconcrete units capable of formation in a masonry block machine,conventional bricks, concrete pavers, natural stone, etc. The facer 10shown is of the concrete type formed in a masonry block machine and hasa decorative face of pleasing appearance as best illustrated in FIG. 2.The facer also has beveled or chamfered corners 12, 12 between the endwalls and rear wall and along one side wall and rear wall corner. Theopposite rear wall and side wall corner is devoid of a bevel or chamferas best illustrated in FIGS. 3, and 4, this due to the inability of ablock machine to conveniently form chamfers on all four rear corners ofa facer.

[0060] Connecting means for co-operation with concrete or otherstructural backing on the rear surface of the facer preferably take theform of integral dove-tail ribs as shown. A single centrally locatedfull rib 14 is shown in FIG. 1 and partial, substantially half ribs 16,16, are also shown in FIG. 1. at the sides of the facer. Dove-tailgrooves 18, 18 are defined between ribs as best illustrated in FIGS. 1and 4.

[0061] Referring now to FIGS. 5-10, the method of the invention isillustrated sequentially. In FIG. 5 a plurality of facers 10, 10 areshown positioned in abutting face down relationship and in a commonplane atop casting bed 20. The casting bed 20 may be rigid or deformableas mentioned. Foam plastic and other materials may be employed in adeformable bed but fine particulate material, such as sand, is preferredand is shown in FIGS. 5-10. Form members 22, 22 establish the peripherallimits of the casting bed. Channels defined between facers are at leastone-half (½) “Y” configurations viewed in cross-section and mayaccommodate sealant as mentioned. As best illustrated in FIG. 6 achamfer 12 on a right hand facer forms a one-half (½) “Y” channel withthe straight face of a left hand facer adjacent thereto.

[0062] In FIGS. 7 and 8, a sealant has been introduced to the channels24 and may comprise a fine particulate material, preferably sand asmentioned above. This may be conveniently accomplished by depositingsand atop the backs of the facers, sweeping the same into the sealantchannels 24, 24 and concurrently sweeping the sand away to clean thebacks of the facers for good adherence to the concrete.

[0063]FIGS. 9 and 10 illustrate the facers 10, 10 with a cementitiousstructural member cast thereabove, conforming to and adhering thereto.Concrete is preferably employed as mentioned but various other materialscapable of being cast in situ may also be used. As best illustrated inFIG. 10, the concrete is formed about the ribs 14, 16 and at the jointstherebetween. The concrete also engages and forms a seal with the wallsof the chamfers and with an elongated narrow vertical surface 25 betweenthe chamfers and the bottoms of the grooves. This prevents water seepagebehind the facers which might otherwise result in loosening and “falloff” of the same over time. Downward penetration of the concrete betweenfacers during pouring and curing is prevented by the sand 26 which formsa seal between the facers as stated.

[0064] In FIGS. 11-13, joints 24 a, 24 a are shown between facers 10,10. The “Y” shaped sealant channels result where adjacent facers areprovided with identical opposing chamfers 12, 12. The method employed isof course identical with regard to FIGS. 5-10. That is, sand isintroduced to the channels as shown at 26. The excess sand may be sweptclean and the concrete or other cementitious material 28 then poured andallowed to cure and harden as shown in FIG. 13, the sand 26 serving itssealing function in each of the channels as stated.

[0065] In FIG. 14, a plurality of facers 10 are shown in a partiallycomplete panel in association with optional spring clips 30, 30. Thespring clips 30, 30 each have a dove-tail configuration complementary tothe cross-section of the ribs 14, 16. That is, a single central rib 14can be interconnected with a second rib 14 in end-to-end relationship asshown. Further, end ribs 16, 16 in side-by-side relationship can also bereadily interconnected by a clip 30 as shown. Clips 30, 30 may beentered about a single rib 14 or a pair of adjacent end ribs 16, 16 inrelative endwise movement and positioned as desired to serve theirinterconnecting function. Preferably, however, the clips 30, 30 areurged downwardly over the ribs in a snap action with opposite legs 32,32 first being spread apart and then contracting to firmly embrace theribs.

[0066] FIGS. 16-18 illustrate a second form of the clips at 30 a and itwill be observed that each of the clip configurations includes openingsas at 34 and 34 a. The openings 34 and 34 a allow concrete to penetrateand adhere to the ribs during pouring and subsequent curing.

[0067] The installation of the clips may be accomplished manually orwith the aid of a tool 36 illustrated in FIGS. 37-40. The tool 36 hasmanually operable handles 38, 38 pivotally connected at 40 and opposingoperating arms 42, 42 each with a small lip 44. The lips 44,44 extendsoutwardly and engage small hooklike members 46, 46 at the ends of thelegs of a clip 30. The hooklike members face inwardly and the lips 44,44 on the tool engage the hooks and spread the legs 32, 32 of the clipsfor easy movement of the same about a rib. Once a clip has beenpositioned about the rib the tool may be released to allow the legs tospring inwardly and snap into firm embracing relationship with one ormore ribs. FIG. 38 shows the release of the clip and the operativemovement of the tool is illustrated in FIG. 39. Once the clips have beeninstalled as shown in FIG. 14, pouring of the concrete may be initiatedas described above.

[0068] The clips 30, 30 a may be employed to ensure firm abuttingengagement of the facers in the embodiment described above with asealant disposed in the recesses or channels at facer joints. Further,that satisfactory results may be achieved with the clips in some caseseven without sealant disposed in the channels between facers. That is,the forces provided by the clips bringing the facers into firmengagement may result in facer joints which are sufficiently tight toprevent penetration of the concrete through the joints and the resultingundesirable flow of small quantities of concrete onto the front surfacesof the facers. These conditions may prevail when facers withparticularly smooth surfaces are employed. Further, it may be possibleto eliminate both the sealant and the clips in certain situations. Hereagain, abutting facers with exceptionally smooth side surfaces mayresult in joints sufficiently tight to prevent concrete penetration.

[0069] A product known as Self Compacting Concrete not requiringvibration may be employed to advantage particularly in this lattermethod embodiment as a structural backing material. In the absence ofvibration, as required with conventional concrete for uniformity and thefilling of small voids such as the sealant channels, there isconsiderable less likelihood of penetration or leakage through the facerjoints.

[0070] In addition to the foregoing, “anti bonding agents” and“retarders” may be applied to the front surfaces of the facers. Thisfacilitates or may completely eliminate cleaning of the facers as afinal step in the process of making the walls or other panels of thepresent invention.

[0071] In certain applications, additional structural integrity andstrength may be required in connecting the facers to the structuralbacking material of the panel. FIGS. 19-22 illustrate an anchor employedfor such purposes. In FIG. 36 the anchor is shown in operative positionon a facer prior to the casting of concrete thereabout. The anchor has abase portion 48 adapted to enter and be retained in a groove 18 asillustrated in FIG. 36. Upstanding portion 50 is adapted to be embeddedin the concrete and, thereby provide structural strength firmlyinterconnecting the facers and the structural backing. As shown, thebase portion takes a generally Z shape with opposing legs 52, 52 adaptedto enter a groove 18 and engage the opposing ribs defining the groove.The upper portion 50 of the anchor includes an integral arm whichextends horizontally with the anchor mounted on the facers and which isalso embedded in the concrete as mentioned. “A chair” for supportingelongated reinforcing members, commonly known as “re-bars”, isillustrated in FIGS. 23-29 at 54. The chair 54 has four (4) legs anddefines a pair of right angularly arranged upwardly open grooves 56, 56at an upper portion thereof. Legs 58, 58 enter the grooves 18, 18 asbest illustrated in FIGS. 27 and 29 and may be of flexible constructionso as to snap into position. The reinforcing members or “re-bars” maythen be mounted in the grooves 56, 56 prior to pouring the concrete sothat the re-bars are thereafter embedded in the concrete.

[0072] FIGS. 30-35 illustrate a re-bar chair for supporting six (6)re-bars in a three (3) each right angular arrangement and FIG. 6 a five(5) and three (3) right angular arrangement.

[0073] In FIG. 41 an insulated panel is illustrated in cross-section andcomprises a plurality of facers 106, 106 in planar arrangement asdescribed above. A relatively thin layer of concrete 50 is then castover the facers with a conventional insulating panel 52 disposedthereabove. Finally, a heavier layer of concrete 54 is cast atop theinsulating panel with transverse connectors 56, 56 embedded in theconcrete and preferably extending from the thin layer of concrete 50through the insulating panel 52 and into the heavier layer of concrete54.

[0074] As will be apparent from the foregoing, a method has beenprovided for forming a composite panel of groutless construction in anextremely simple and yet highly efficient manner. The method mayobviously be employed at economic advantage in the construction ofcomposite tilt-up walls, precast and other panels having a wide varietyof facial characteristics with a minimum of manual labor and anaesthetically pleasing and/or functionally improved end result.

1. A method of forming a composite panel with a facade comprising aplanar arrangement of thin facers on a body of structural backingmaterial; said method comprising the steps of providing a substantiallyflat casting bed, providing a plurality of facers each with a recessalong at least a major portion of a corner extending along and betweenits side and rear walls, arranging the plurality of individual facers inabutting relationship atop the casting bed and in a selected geometricpattern in a face-down planar configuration so that recesses on thefacers open rearwardly and define narrow elongated channels at jointsbetween contiguous facers, casting structural material behind the facersto both conform to and adhere to the rear surfaces thereof and form acomposite panel, the structural material forming a seal with the wallsof the recesses at joints between the facers.
 2. A method of forming acomposite panel as set forth in claim 1 wherein the facers have arectangular configuration, and wherein the rear corners thereof arechamfered along each rear end wall comer and at least one rear-side wallcorner.
 3. A method of forming a composite panel as set forth in claim 2wherein each chamfer has a flat angularly inclined surface extendingbetween adjacent side and rear facer surfaces.
 4. A method of forming acomposite panel or set forth in claim 1 including the step of depositinga sealant in the channels between facers.
 5. A method of forming acomposite panel as set forth in claim 4 wherein fine particulatematerial is used as a sealant.
 6. A method of forming a composite panelas set forth in claim 5 wherein the fine particulate material is sand.7. A method of forming a composite panel as set forth in claim 6 whereinthe sand is deposited on the rear surfaces of the facers and swept intothe sealant channels with the rear surfaces of the facers swept clean.8. A method of forming a composite panel as set forth in claim 4 whereinthe sealant takes the form of a hardenable liquid material deposited inthe sealant channels and then allowed to at least partially harden so asto prevent the structural material from flowing through the jointsbetween the facers during casting.
 9. A method of forming a compositepanel as set forth in claim 1 wherein a fine particulate material isemployed in providing a deformable casting bed.
 10. A method of forminga composite panel as set forth in claim 4 wherein the fine particulatematerial is sand.
 11. A method of forming a composite panel as set forthin claim 1 wherein a compressible foam plastic material is employed inproviding the casting bed.
 12. A method of forming a composite panel asset for the in claim 1 including providing a plurality of clips and ribson the backs of facers and installing the clips in interconnectingrelationship with ribs on contiguous facers to force the facers intofirm engagement and prevent concrete leakage therebetween during castingof the structural material.
 13. A method of forming a composite panel asset forth in claim 12 where some of the clips are installed ininterconnecting relationship on ribs of contiguous facers arranged inend-to-end relationship and others are installed on ribs of contiguousfacers arranged in side-by-side relationship.
 14. A method of forming acomposite panel as set forth in claim 13 wherein dove-tailed ribs areprovided and wherein the spring clips are provided each with a generallydove-tail configuration in cross-section and with short opposing sidelegs defining an opening for receiving a dove-tailed rib, the legs ofeach clip being inwardly inclined toward the mouth of the clip opening,and wherein the clips are snapped into interconnecting positions on theribs in movement of the clips relative to the ribs, the clips receivingthe ribs and being thus mounted in embracing relationship with the ribs.15. A method of forming a composite panel as set forth in claim 14wherein the clips are provided with vertical through openings fordownward entry of the structural material during casting.
 16. A methodof forming a composite panel as set forth in claim 15 including the stepof spreading and engaging the legs of each clip with a rib and thenreleasing and thus connecting the same in embracing relationship withthe rib.
 17. A method of forming a composite panel as set forth in claim16 and including the steps of providing a tool for conveniently manuallyspreading and releasing the legs of a clip and thus efficiently snappingthe clips into embracing positions on the ribs.
 18. A method of forminga composite panel as set forth in claim 1 wherein a retarder is appliedto the front surfaces of the facers.
 19. A method of forming a compositepanel as set forth in claim 1 wherein an “anti bonding agent” is appliedto the front surfaces of the facers.
 20. A method of forming a compositepanel as set forth in claim 1 wherein Self Compacting Concrete isemployed as structural backing material.
 21. A method of forming acomposite panel as set forth in claim 1 wherein the facers are providedwith integral rearwardly and upwardly projecting connecting means whichare embedded in the structural backing material after casting to providefor enhanced structural integrity of the panel.
 22. A method of forminga composite panel as set forth in claim 21 wherein the connecting meanstake the form of a series of ribs integral with the bodies of thefacers.
 23. A method of forming a composite panel as set forth in claim22 wherein the ribs on the facers take a generally dove-tailconfiguration viewed in cross-section with complementary generallydove-tailed spaces therebetween for enhanced strength of connection withthe structural backing material.
 24. A method of forming a compositepanel as set forth in claim 23 wherein a plurality of anchors areprovided and installed each with a flexible base portion adapted to snapinto engagement with at least one rib and each with a body portionprojecting therefrom so as to be embedded in structural material duringcasting.
 25. A method of forming a composite panel as set forth in claim24 wherein the anchors each have base portions adapted to snap intoengagement in dove-tailed grooves between adjacent ribs.
 26. A method offorming a composite panel as set forth in claim 23 wherein a pluralityof supports for reinforcing members are provided and mounted on thebacks of the facers.
 27. A method of forming a composite panel as setforth in claim 23 wherein the supports are spring mounted on one or moreribs.
 28. A method of forming a composite panel as set forth in claim 23wherein the supports have base portions adapted to slide in an endwisedirection into dove-tail inter-rib grooves.
 29. A method of forming acomposite panel as set forth in claim 23 wherein each support takes achair-like configuration with an upper reinforcing member mountingportion and depending flexible legs adapted to be compressed inwardlytoward each other with lower end portions engaging adjacent ribs.
 30. Amethod of forming a composite panel as set forth in claim 29 whereineach support mounting portion has at least one open groove for receivingand supporting a portion of a reinforcing bar.
 31. A method of forming acomposite panel as set forth in claim 30 wherein each support mountingportion has two right angularly arranged open grooves for receiving andsupporting a portion of a reinforcing bar.
 32. A method of forming acomposite panel as set forth in claim 30 wherein each support mountingportion has two pairs of right angularly arranged open grooves forreceiving and supporting a portion of a reinforcing bar, each pair ofgrooves comprising of at least three (3) aligned grooves.
 33. A methodof forming a composite panel as set forth in claim 30 wherein eachsupport mounting portion has two pairs of right angularly arranged opengrooves for receiving and supporting a portion of a reinforcing bar, onepair of grooves comprising three (3) aligned grooves and the othercomprising five (5) aligned grooves.
 34. A method of forming a compositepanel as set forth in claim 30 , wherein the structural material takesthe form of concrete.
 35. A method of forming a composite tilt-up wallwith a facade comprising a planar arrangement of thin decorativerectangular facers on a body of concrete structural backing material;said method comprising the steps of providing a flat substantiallyhorizontal casting bed of sand, providing a plurality of facers eachwith chamfers along at least the corners between end and rear walls andat least one side and rear wall, arranging the individual facers inabutting relationship atop the casting bed and in a selected geometricpattern in a face-down planar configuration so that the chamfers on thefacers open upwardly and define narrow elongated sealant channelsbetween contiguous facers, depositing sand on the rear surfaces of thefacers and in the channels therebetween, sweeping the sand from the rearsurfaces of the facers, casting concrete atop the facers to adhere tothe rear surfaces thereof and to form a composite wall, and tilting thewall to an upright position.
 36. A method of forming a composite panelas set forth in claim 1 wherein an insulating panel is embedded withinthe structural backing material with a first portion of the latterbetween the panel and the facers and a second portion on an oppositeside of the panel.
 37. A method of forming a composite panel as setforth in claim 36 wherein a plurality of connectors are embedded in theinsulating panel and extend in opposite directions into both the firstand second portions of the structural backing material.